Display apparatus and method of manufacturing the same

ABSTRACT

Provided are a method of manufacturing a display apparatus and the display apparatus. A method of manufacturing a display apparatus includes preparing a first substrate including a display; adhering a second substrate to the first substrate by using a sealing element; exposing the sealing element by using a blocking member including a plurality of blocking patterns arranged apart from one another; and cutting the first substrate and the second substrate along portions thereof inside the blocking member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/997,650, filed Jun. 4, 2018, which is a continuation of U.S. patentapplication Ser. No. 15/273,569, filed Sep. 22, 2016, now U.S. Pat. No.9,989,811, issued on Jun. 5, 2018, which claims priority to and thebenefit of Korean Patent Application No. 10-2015-0166409, filed Nov. 26,2015, the entire content of each of which is incorporated herein byreference.

BACKGROUND 1. Field

Aspects of one or more embodiments relate to a display apparatus and amethod of manufacturing the same.

2. Description of the Related Art

Since display apparatuses including an organic light-emitting displayapparatus and a liquid crystal display apparatus may be manufactured asthin display apparatuses and/or flexible display apparatuses, variousresearch into them is being made. Such a display apparatus may have astructure in which a display is between a first substrate and a secondsubstrate as the first substrate having formed thereon the display isadhered to the second substrate by using an encapsulating element.

However, in such a display apparatus in the related art, a firstsubstrate and/or a second substrate may be easily damaged by an externalshock.

SUMMARY

According to an aspect of one or more embodiments, a display apparatushas improved shock resistance, and a method of manufacturing the same isprovided.

Additional aspects will be set forth in part in the description whichfollows and, in part, will be apparent from the description, or may belearned by practice of the presented embodiments.

According to one or more embodiments, a method of manufacturing adisplay apparatus includes preparing a first substrate including adisplay; adhering a second substrate to the first substrate by using asealing element; exposing the sealing element by using a blocking memberincluding a plurality of blocking patterns arranged apart from oneanother; and cutting the first substrate and the second substrate alongportions thereof inside the blocking unit.

The blocking member may overlap portions of the sealing element.

The blocking member may overlap outer end portions of the sealingelement.

The adhering of the second substrate to the first substrate may includearranging the second substrate on the first substrate; and arranging theblocking member on the second substrate such that the blocking memberoverlaps a portion of the sealing element.

The plurality of blocking patterns may be sequentially arranged apartfrom one another in a widthwise direction of the sealing element.

At least a portion of the blocking member may include a first blockingpattern at least partially overlapping the sealing element; and a secondblocking pattern arranged apart from the first blocking pattern in awidthwise direction of the sealing element.

A width of the first blocking pattern in the widthwise direction may beequal to or greater than a width of the second blocking pattern in thewidthwise direction.

At least one of the plurality of blocking patterns may have a linearshape or a dot-like shape.

The plurality of blocking patterns may be formed of a metal.

The method may further include forming a touch screen conductive patternon the second substrate, wherein the plurality of blocking patterns maybe formed during the forming of the touch screen conductive pattern.

A distance between blocking patterns adjacent to each other from amongthe plurality of blocking patterns may be within about 7 μm.

The blocking member may overlap three surface portions of the sealingelement.

In the exposing of the sealing element, a portion of the sealing elementnot overlapping the blocking member may be exposed, and a portion of thesealing element overlapping the blocking member may not be exposed.

The width of the exposed portion of the sealing element may be less thanor equal to 800 μm.

In the cutting of the first substrate and the second substrate, thefirst substrate and the second substrate may be cut such that a width ofthe display apparatus measured with respect to the sealing element isgreater than a width of the first substrate or the second substrate.

In the cutting of the first substrate and the second substrate, thefirst substrate may be cut such that the width of the first substrateincreases in a direction from the outer surface of the first substratetoward the inner surface of the first substrate.

In the cutting of the first substrate and the second substrate, thefirst substrate may be cut such that a first constant portion having aconstant width and a first increasing portion having an increasing widthare defined.

In the cutting of the first substrate and the second substrate, thefirst constant portion may be cut by using a cutting wheel.

The first increasing portion may be naturally cut due to the internalstress of the first substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects will become apparent and more readilyappreciated from the following description of some embodiments, taken inconjunction with the accompanying drawings in which:

FIGS. 1 through 8 are schematic diagrams showing operations of a methodof manufacturing a display apparatus, according to an embodiment;

FIG. 9 is a sectional view of a display apparatus according to anotherembodiment;

FIG. 10 is a schematic sectional diagram showing an operation of amethod of manufacturing a touch screen display apparatus according to anembodiment;

FIG. 11 is a schematic sectional diagram showing an operation of amethod of manufacturing a display apparatus according to anotherembodiment;

FIGS. 12A through 12G are schematic diagrams showing various examples ofa blocking unit according to further embodiments;

FIGS. 13 and 14 are a schematic plan diagram and a schematic sectionaldiagram, respectively, showing an operation of a method of manufacturinga display apparatus according to another embodiment; and

FIG. 15 is a schematic sectional diagram showing an operation of amethod of manufacturing a display apparatus, according to anotherembodiment.

DETAILED DESCRIPTION

Reference will now be made in further detail to some embodiments,examples of which are illustrated in the accompanying drawings, whereinlike reference numerals refer to like elements throughout. In thisregard, the present embodiments may have different forms and should notbe construed as being limited to the descriptions set forth herein.Accordingly, the embodiments are described below, by referring to thefigures, merely to explain aspects of the present description. As usedherein, the term “and/or” includes any and all combinations of one ormore of the associated listed items. Expressions such as “at least oneof,” when preceding a list of elements, modify the entire list ofelements and do not modify the individual elements of the list.

Hereinafter, the inventive concept will be described in further detailby explaining some example embodiments of the invention with referenceto the attached drawings.

It will be understood that when a layer, region, or component isreferred to as being “formed on” another layer, region, or component, itcan be directly or indirectly formed on the other layer, region, orcomponent. That is, for example, intervening layers, regions, orcomponents may be present. Sizes of elements in the drawings may beexaggerated for convenience of explanation. In other words, since sizesand thicknesses of components in the drawings may be arbitrarilyillustrated for convenience of explanation, the following embodimentsare not limited thereto.

In the following examples, the x-axis, the y-axis, and the z-axis arenot limited to three axes of the rectangular coordinate system, and maybe interpreted in a broader sense. For example, the x-axis, the y-axis,and the z-axis may be perpendicular to one another, or may representdifferent directions that are not perpendicular to one another.

FIGS. 1 through 8 are schematic diagrams showing operations of a methodof manufacturing a display apparatus, according to an embodiment.

According to a method of manufacturing a display apparatus, a firstsubstrate 110 is prepared. The first substrate 110 (e.g., a glasssubstrate) includes a first inner surface 111 and a first outer surface112, as shown in FIG. 1, where the first outer surface 112 may beunderstood as a surface that becomes an outer surface after the firstsubstrate 110 is adhered to a second substrate 120 later. Side surfacesof the first substrate 110 may be understood as surfaces interconnectingthe first inner surface 111 and the first outer surface 112 together.

After the first substrate 110 is prepared as described above, a display130 including a display element is formed on the first inner surface 111of the first substrate 110, as shown in FIG. 1. The display element maybe an organic light-emitting display element, a liquid crystal displayelement, or one of various other display elements. Furthermore, variousother modifications may be made thereto. For example, the display 130may further include electronic elements, such as a thin-film transistorand/or a capacitor, other than display elements.

Other than the first substrate 110, a second substrate 120 (e.g., aglass substrate) (see FIG. 2A and FIG. 2B) is also prepared. The secondsubstrate 120 includes a second inner surface 121 and a second outersurface 122. The first substrate 110 and the second substrate 120 may beprepared concurrently (e.g., simultaneously). Alternatively, either thefirst substrate 110 or the second substrate 120 may be prepared first,and then the other one may be prepared. However, the inventive conceptis not limited thereto.

As shown in FIG. 2A, the first substrate 110 is adhered to the secondsubstrate 120 by using a sealing element 140. The sealing element 140may be arranged between the first inner surface 111 of the firstsubstrate 110 and the second inner surface 121 of the second substrate120 and may surround the display 130, thereby adhering the firstsubstrate 110 and the second substrate 120 to one another. In anembodiment, the sealing element 140 may have a width from about 200 μmto about 800 μm and a thickness from about 2 μm to about 10 μm.

The sealing element 140 may include frit, for example. Frit is glassmaterial used to form glass and may be cured after exposure to a laserbeam. The main components of the frit may include 15˜40 wt % V₂O₅, 10˜30wt % TeO₂, 1˜15 wt % P₂O₅, 1˜15 wt % BaO, 1˜20 wt % ZnO, 5˜30 wt % ZrO₂,5˜20 wt % WO₃, and 1˜15 wt % BaO, where at least one or more of Fe₂O₃,CuO, MnO, Al₂O₃, Na₂O, and Nb₂O₅ may be added thereto. The frit havingthe above-stated composition may have a thermal expansion coefficient of40˜100×10⁻⁷/° C. and a glass transition temperature from about 250° C.to about 400° C. If the frit as described above is used, after the fritis cured later, a cured portion may induce internal stress distributionin the first substrate 110 and the second substrate 120 as describedbelow, and, thus, when the first substrate 110 and the second substrate120 are cut, cut surfaces may become curved surfaces. Further detaileddescriptions thereof are provided below.

The first substrate 110 may be adhered to the second substrate 120 byusing the sealing element 140 in any of various ways. In an embodiment,for example, after the sealing element 140 is arranged along the edgesof the second inner surface 121 of the second substrate 120, the firstsubstrate 110 may be adhered to the second substrate 120. In anotherembodiment, after the sealing element 140 is arranged along the edges ofthe first inner surface 111 of the first substrate 110 and completelysurrounds the display 130, the first substrate 110 may be adhered to thesecond substrate 120. In any case, as the first substrate 110 is adheredto the second substrate 120, the sealing element 140 ends up with curvedside surfaces as shown in FIG. 2A. FIG. 2A shows that the side surfacesof the sealing element 140 are curved outward.

As shown in FIGS. 2A and 2B, a blocking unit or blocking member 150 maybe formed on the second outer surface 122 of the second substrate 120.As described below, the blocking unit 150 may block transmission of alaser beam to prevent a portion of the sealing element 140 from beingexposed while the sealing element 140 is being exposed. To this end, theblocking unit 150 may overlap a portion of the sealing element 140. Forexample, the blocking unit 150 may overlap an outer end portion of thesealing element 140. As shown in FIG. 2B, the blocking unit 150 mayoverlap three surface portions of the sealing element 140.

In an embodiment, the blocking unit 150 may reflect an incident laserbeam to block transmission of the laser beam. However, a reflected laserbeam may damage equipment like a laser source. Therefore, it is desiredto reduce reflection of a laser beam and not expose the sealing element140. To this end, the blocking unit 150 according to an embodiment mayinclude a plurality of blocking patterns 152 arranged apart from oneanother. In an embodiment, a distance “d” between every two blockingpatterns 152 adjacent to each other among the plurality of blockingpatterns 152 may be within about 7 μm. Since the distance “d” betweenthe blocking patterns 152 is within about 7 μm, even if a laser beam isincident via a space between the blocking patterns 152, the sealingelement 140 may not be exposed.

In an embodiment, the plurality of blocking patterns 152 may besequentially arranged apart from one another in a widthwise direction ofthe sealing element 140 (e.g., an x-axis direction). For example, theblocking unit 150 may include a first blocking pattern 152 a, which atleast partially overlaps the sealing element 140, and a second blockingpattern 152 b, which is arranged apart from the first blocking pattern152 a in the widthwise direction of the sealing element 140 (e.g., thex-axis direction). The first blocking pattern 152 a and the secondblocking pattern 152 b may be arranged next to each other in alengthwise direction of the sealing element 140. The first blockingpattern 152 a and the second blocking pattern 152 b may have linearshapes. However, the inventive concept is not limited thereto.

In an embodiment, the first blocking pattern 152 a and the secondblocking pattern 152 b may have a same width “w.” However, the inventiveconcept is not limited thereto. Furthermore, the blocking pattern 152may be formed of a metal capable of reflecting a laser beam.

The blocking unit 150 as described above is formed on the second outersurface 122 of the second substrate 120, and the second substrate 120including the blocking unit 150 thereon may be adhered to the firstsubstrate 110. Alternatively, after the second substrate 120 is adheredto the first substrate 110, the blocking unit 150 may be formed on thesecond substrate 120 and overlaps a portion of the sealing element 140.

Next, as shown in FIG. 3, the sealing element 140 may be exposed. In anembodiment, only inner portions of the sealing element 140 may beexposed by a laser beam. The output power of the laser beam may be fromabout 50 Watts to about 60 Watts and a uniformity thereof may be fromabout 110% to about 95%.

Even if a laser beam is irradiated to the sealing element 140, a laserbeam incident to the blocking unit 150 is reflected, and thus a portion142 (hereinafter, referred to as the unexposed portion) of the sealingelement 140 which overlaps the blocking unit 150 may not be exposed.Therefore, only a portion 141 (hereinafter, referred to as the exposedportion) of the sealing element 140 which does not overlap the blockingunit 150 may be exposed.

Next, as shown in FIGS. 4 and 5, the first substrate 110, the sealingelement 140, and the second substrate 120 may be cut. In an embodiment,for example, a cutting operation may start at points of the firstsubstrate 110 and the second substrate 120 that are closer to thedisplay 130 than the boundary (P2, refer to FIG. 4) between the exposedportion 141 and the unexposed portion 142 of the sealing element 140,e.g., points of the first outer surface 112 and the second outer surface122 corresponding to a point P1 or P3 of the sealing element 140.

The cutting start point will be described below in further detail. Thecenter of the exposed portion 141 of the sealing element 140 may bereferred to as a first point P1, the boundary between the exposedportion 141 and the unexposed portion 142 of the sealing element 140 maybe referred to as a second point P2, and the center of the portionbetween the first point P1 and the second point P2 may be referred to asa third point P3. Here, the cutting start point may be points of thefirst substrate 110 and the second substrate 120 corresponding to thethird point P3 or points of the first substrate 110 and the secondsubstrate 120 corresponding to a point between the second point P2 andthe third point P3. FIG. 5 shows an example in which a cutting operationstarts at points of the first substrate 110 and the second substrate 120corresponding to the third point P3 by using at least one of cuttingwheels 310 and 320.

FIG. 6 is a sectional diagram showing a region “A” of FIG. 5 in closerdetail, showing internal stress in the first substrate 110 and thesecond substrate 120 induced by the sealing element 140. In FIG. 6, thethin dashed lines indicate internal stress, whereas the thick dashedline indicates a cutting line CL. As described above with reference toFIG. 3, when only the inner portion 141 of the sealing element 140 isexposed, after the sealing element 140 is plasticized, the exposedportion 141 applies stress to the first substrate 110 and the secondsubstrate 120. On the other hand, the unexposed portion 142 onlycontacts the first substrate 110 and the second substrate 120 and doesnot apply stress to the first substrate 110 and the second substrate120. That is, although the exposed portion 141 applies stress as thevolume of the exposed portion 141 is reduced while being exposed andplasticized, the unexposed portion 142 does not undergo such a change.Therefore, the internal stress is distributed in the first substrate 110and the second substrate 120 as indicated by the thin dashed lines inFIG. 6.

At such a state, as shown in FIG. 5, a cutting operation may start on atleast one of the second outer surface 122 and the first outer surface112 at points of the first substrate 110 and the second substrate 120corresponding to the third point P3 of the sealing element 140, forexample, by using at least one of the cutting wheels 310 and 320.

Here, due to the internal stress of the first substrate 110 and thesecond substrate 120, the first substrate 110 and the second substrate120 may be naturally cut along the cutting line CL of FIG. 6 to havecurved side surfaces, and thus a display apparatus, as shown in FIG. 7,may be manufactured. Cut shapes of the first substrate 110 and thesecond substrate 120 will be described below in further detail withreference to FIG. 8, which is an enlarged partial sectional diagramshowing a region “B” of FIG. 7 in closer detail. When the firstsubstrate 110 and the second substrate 120 are cut, the first substrate110 and the second substrate 120 may be cut to have a pre-set sidesurface shape.

In an embodiment, the first substrate 110 may be cut, such that aportion of the first substrate 110 corresponding to the display 130includes a first constant portion CR1 having a width constant in adirection from the first outer surface 112 to the first inner surface111 (e.g., a positive y-axis direction), and a first increasing portionIR1 having a width increasing in the same direction. Here, in the caseshown in FIGS. 7 and 8, the term “width” may be understood as a lengthin an x-axis direction. Furthermore, a portion corresponding to thedisplay 130 is not limited to a portion directly above the display 130,but may also include a portion corresponding to the sealing element 140(141 in FIGS. 7 and 8). As the first substrate 110 is cut as describedabove, side surfaces of the first substrate 110 may have a firstconstant side surface 110 b, which is adjacent to the first outersurface 112 and is substantially perpendicular to the first outersurface 112, and a first increasing side surface 110 a, which is curvedoutward in a direction (e.g., the positive y-axis direction) from thefirst constant side surface 110 b to the first inner surface 111 of thefirst substrate 110. Here, the first constant side surface 110 b refersto a side surface of the first constant portion CR1 of the firstsubstrate 110, and the first increasing side surface 110 a refers to aside surface of the first increasing portion IR1 of the first substrate110.

Furthermore, the second substrate 120 may be cut, such that a portion ofthe second substrate 120 corresponding to the display 130 includes asecond constant portion CR2 having a width constant in a direction fromthe second outer surface 122 to the second inner surface 121 (e.g., anegative y-axis direction), and a second increasing portion IR2 having awidth increasing in the same direction. Here, in the cases shown inFIGS. 7 and 8, the term “width” may be understood as a length in anx-axis direction. Furthermore, a portion corresponding to the display130 is not limited to a portion directly above the display 130, but mayalso include a portion corresponding to the sealing element 140 (141 inFIGS. 7 and 8). As the second substrate 120 is cut as described above,side surfaces of the second substrate 120 may have a second constantside surface 120 b, which is adjacent to the second outer surface 122and is substantially perpendicular to the second outer surface 122, anda second increasing side surface 120 a, which is curved outward in adirection (e.g., the negative y-axis direction) from the second constantside surface 120 b to the second inner surface 121 of the secondsubstrate 120. Here, the second constant side surface 120 b refers to aside surface of the second constant portion CR2 of the second substrate120, and the second increasing side surface 120 a refers to a sidesurface of the second increasing portion IR2 of the second substrate120.

Therefore, in an embodiment, the side surfaces of the first substrate110 and the second substrate 120 are curved as shown in FIGS. 7 and 8.The cutting line CL may extend along the boundary between the exposedportion 141 and the unexposed portion 142 of the sealing element 140 asshown in FIG. 6. This is because the exposed portion 141 adheres thefirst substrate 110 to the second substrate 120, but the unexposedportion 142 only contacts the first substrate 110 and the secondsubstrate 120 and does not adhere the first substrate 110 to the secondsubstrate 120.

If a further cutting operation is not naturally performed even after thefirst constant side surface 110 b (refer to FIG. 8) and the secondconstant side surface 120 b (refer to FIG. 8) are formed at the firstsubstrate 110 and the second substrate 120, the first substrate 110 andthe second substrate 120 may be naturally cut along the cutting line CL,as shown in FIG. 6, to have curved side surfaces by applying a smallamount of force or shock to the first substrate 110 and/or the secondsubstrate 120. Here, it may be understood that the remaining portions ofthe cutting line CL, other than portions substantially perpendicular tothe first outer surface 112 of the first substrate 110 and the secondouter surface 122 of the second substrate 120, are substantiallyperpendicular to the lines (i.e. the thin dashed lines of FIG. 6)indicating the internal stress in the first substrate 110 and the secondsubstrate 120.

In the case of forming the first constant side surface 110 b (refer toFIG. 8) and the second constant side surface 120 b (refer to FIG. 8) atthe first substrate 110 and the second substrate 120, cutting wheels 310and 320 may be arranged respectively on the second outer surface 122 ofthe second substrate 120 and the first outer surface 112 of the firstsubstrate 110, as shown in FIG. 5, and the first substrate 110 and thesecond substrate 120 may be concurrently (e.g., simultaneously) cutinwardly.

As described above, the first substrate 110 and the second substrate 120may be naturally cut along the remaining portions of the cutting line CLof FIG. 6 other than the portions substantially perpendicular to thefirst outer surface 112 of the first substrate 110 and the second outersurface 122 of the second substrate 120 due to the internal stress ofthe first substrate 110 and the second substrate 120. In an embodiment,if only the first constant side surface 110 b (refer to FIG. 8) of thefirst substrate 110 is formed first, and the second constant sidesurface 120 b (refer to FIG. 8) of the second substrate 120 is formedlater, the first substrate 110 and the second substrate 120 may be cutdue to the internal stress as soon as the first constant side surface110 b (refer to FIG. 8) of the first substrate 110 is formed. In thiscase, the second constant side surface 120 b (refer to FIG. 8) of thesecond substrate 120 that is substantially perpendicular to the secondouter surface 122 of the second substrate 120 may not be normallyformed.

Therefore, the cutting wheels 310 and 320 may be arranged respectivelyon the second outer surface 122 of the second substrate 120 and thefirst outer surface 112 of the first substrate 110, and the firstsubstrate 110 and the second substrate 120 may be concurrently (e.g.,simultaneously) cut inwardly. As a result, the first constant sidesurface 110 b (refer to FIG. 8) and the second constant side surface 120b (refer to FIG. 8) may be respectively formed at the first substrate110 and the second substrate 120.

In an embodiment, in a display apparatus manufactured as describedabove, a curvature radius of an inner side surface 141 b of the sealingelement 140 may be less than a curvature radius of an outer side surface141 a of the sealing element 140, as shown in FIG. 8.

As the sealing element 140 is arranged and the first substrate 110 isadhered to the second substrate 120 as described above, the sealingelement 140 has curved side surfaces, as shown in FIG. 2. Therefore, theinner side surface 141 b of the sealing element 140 shown in FIG. 8maintains such a curved shape.

Meanwhile, as shown in FIGS. 5 and 6, when the first substrate 110 andthe second substrate 120 are cut after the sealing element 140 isexposed, while the first substrate 110 and the second substrate 120 arebeing cut along the cutting line CL, the sealing element 140 is cut at apoint near the boundary between the exposed portion 141 and theunexposed portion 142. Here, as shown in FIG. 8, the first increasingside surface 110 a, which is a side surface of the first increasingportion IR1 of the first substrate 110, the outer side surface 141 a ofthe sealing element 140, and the second increasing side surface 120 a,which is a side surface of the second increasing portion IR2 of thesecond substrate 120, form a continuous curved surface. Here, the outerside surface 141 a of the sealing element 140 is arranged near thevertex of the curved surface, and thus the curvature radius of the outerside surface 141 a of the sealing element 140 becomes greater than thecurvature radius of the inner side surface 141 b of the sealing element140 facing the display 130. Side surfaces of a display apparatusmanufactured according to the method according to the present embodimenthave a curved shape overall, as shown in FIGS. 7 and 8. When sidesurfaces of a display apparatus have a curved shape, the first substrate110 and the second substrate 120 may be significantly less likely to bedamaged by an external shock, as compared to a case in which a displayapparatus has flat side surfaces perpendicular to the first outersurface 112 of the first substrate 110 or the second outer surface 122of the second substrate 120. It may be understood that, since the curvedside surfaces function like an arch structure, shock resistance, andmore particularly, lateral shock resistance, is improved. Therefore, adisplay apparatus with excellent shock resistance may be embodied.

To this end, the first increasing portion IR1 may be greater than thefirst constant portion CR1 in the thickness of the first substrate 110(e.g., in the positive y-axis direction). For example, the firstconstant portion CR1 may be less than or equal to half of the firstincreasing portion IR1 in the thickness of the first substrate 110(e.g., in the positive y-axis direction). In the same regard, the secondconstant portion CR2 may be less than or equal to half of the secondincreasing portion IR2 in the thickness of the second substrate 120(e.g., in the positive y-axis direction).

In a display apparatus manufactured according to the method of thepresent embodiment, as shown in FIGS. 7 and 8, the first substrate 110includes the first constant portion CR1, which is a portion of the firstsubstrate 110 corresponding to the display 130 and having a constantwidth in a direction (e.g., the positive y-axis direction) from thefirst outer surface 112 toward the first inner surface 111. Therefore,at the first constant portion CR1, the first outer surface 112 and thefirst constant side surface 110 b of the first substrate 110 meet eachother substantially perpendicularly, and the boundary between the firstouter surface 112 and the first constant side surface 110 b of the firstsubstrate 110 becomes clear. As a result, the first outer surface 112 ofthe first substrate 110 is clearly defined, and, thus, in the case ofattaching a functional film, such as an anti-reflection film, atemporary protection film, or a polarizing film, onto the first outersurface 112 of the first substrate 110, it may be easy to attach thefunctional film to cover the entire first outer surface 112 and not tocover side surfaces of the first substrate 110, that is, the firstconstant side surface 110 b of the first substrate 110.

In an embodiment, the same above-described aspect applies to the secondsubstrate 120. In a display apparatus manufactured according to themethod of the present embodiment, as shown in FIGS. 7 and 8, the secondsubstrate 120 includes the second constant portion CR2, which is aportion of the second substrate 120 corresponding to the display 130 andhaving a constant width in a direction (e.g., the negative y-axisdirection) from the second outer surface 122 toward the second innersurface 121. Therefore, at the second constant portion CR2, the secondouter surface 122 and the second constant side surface 120 b of thesecond substrate 120 meet each other substantially perpendicularly, andthe boundary between the second outer surface 122 and the secondconstant side surface 120 b of the second substrate 120 becomes clear.As a result, the second outer surface 122 of the second substrate 120 isclearly defined, and, thus, in the case of attaching a functional film,such as an anti-reflection film, a temporary protection film, or apolarizing film, onto the second outer surface 122 of the secondsubstrate 120, it may be easy to attach the functional film to cover theentire second outer surface 122 and not to cover side surfaces of thesecond substrate 120, that is, the second constant side surface 120 b ofthe second substrate 120.

FIG. 9 is a sectional view of a display apparatus according to anotherembodiment. As shown in FIG. 9, the first substrate 110 and the secondsubstrate 120 may include only increasing side surfaces without or withlittle constant portions. Therefore, side surfaces of the displayapparatus may form curved surfaces. To form the increasing sidesurfaces, outer surfaces of the first substrate 110 and the secondsubstrate 120 may be slightly cut by using a cutting wheel. Furthermore,by applying a small amount of force or shock to the first substrate 110and the second substrate 120, the first substrate 110 and the secondsubstrate 120 may be naturally cut to have convex side surfaces due tointernal stress thereof.

In an embodiment, in case of manufacturing a display apparatus, it maybe considered to manufacture a display apparatus having a touch screenfunction. To embody a touch screen function, a touch screen conductivepattern is formed on the second outer surface 122 of the secondsubstrate 120. Here, the blocking unit 150 may be concurrently (e.g.,simultaneously) formed during formation of the touch screen conductivepattern, and, thus, the blocking unit 150 may be formed withoutperforming an additional operation.

FIG. 10 is a schematic sectional diagram showing an operation of amethod of manufacturing a touch screen display apparatus according to anembodiment. In FIG. 10, a touch screen conductive pattern 224 is onlypartially shown for convenience of explanation. Of course, the blockingunit 150 may be removed from the display apparatus when the firstsubstrate 110 and the second substrate 120 are cut later. A touch screenconductive pattern and/or the blocking unit 150 may be formed on thesecond outer surface 122 of the second substrate 120 before the secondsubstrate 120 is adhered to the first substrate 110.

As shown in FIG. 10, if the touch screen conductive pattern 224 is onthe second outer surface 122 of the second substrate 120, other than theblocking unit 150, the touch screen conductive pattern 224 may alsoblock a laser beam like the blocking unit 150. Therefore, only theportion 141 of the sealing element 140, but not the edge portion 142 andanother edge portion 143, may be exposed to a laser beam.

FIG. 11 is a schematic sectional diagram showing an operation of amethod of manufacturing a display apparatus according to anotherembodiment.

As shown in FIG. 11, a display apparatus may be manufactured by using aphototransmissive plate 210 including the blocking unit 150. In FIG. 3,the blocking unit 150 is formed on the second substrate 120. However,the inventive concept is not limited thereto. As shown in FIG. 11, thephototransmissive plate 210 may be arranged, such that the blockingunits 150 overlap edge portions of the sealing element 140. Next, alaser beam may be irradiated to the sealing element 140. The firstportion 141 of the sealing element 140 may be exposed, whereas thesecond portion 142 of the sealing element 140 may not be exposed.

As described above, by using the blocking unit 150 including theplurality of blocking patterns 152, transmission and reflection of alaser beam may be suitably controlled. Therefore, the sealing element140 may be prevented from being exposed, and degradation of equipment,such as a laser source, may be reduced. The blocking unit 150 may haveany of various shapes.

FIGS. 12A through 12G are schematic diagrams showing various examples ofthe blocking unit 150 according to further embodiments. The blockingunit 150 shown in FIG. 2B consists of a plurality of linear blockingpatterns 152. Furthermore, the plurality of blocking patterns 152 mayhave a same width. However, the inventive concept is not limitedthereto. In an embodiment, as shown in FIG. 12A, among the plurality ofblocking patterns 152, the width of the blocking pattern 152 arrangedclose to the display 130 may be greater than the width of the blockingpattern 152 arranged farther from the display 130. In an embodiment, thefarther the blocking pattern 152 is arranged from the display 130, thesmaller the width of the blocking patterns 152 may become. However, theinventive concept is not limited thereto. In another embodiment, forexample, the closer the blocking pattern 152 is arranged to the display130, the smaller the width of the blocking patterns 152 may become. Inanother embodiment, the blocking patterns 152 may have irregular widthsdifferent from one another.

In another embodiment, as shown in FIG. 12B, the blocking unit 150 mayinclude dot-like blocking patterns 152. In an embodiment, the blockingpatterns 152 arranged at regions adjacent to the display 130 may have alinear shape, and the blocking patterns 152 arranged far from thedisplay 130 may have a dot-like shape, or vice versa.

In further embodiments, as shown in FIGS. 12C through 12F, the blockingunit 150 may not be arranged at corners of the sealing element 140. Inanother embodiment, as shown in FIG. 12G, the blocking unit 150 may havea mesh-like shape including a plurality of openings “h.”

FIGS. 13 and 14 are a schematic plan diagram and a schematic sectionaldiagram showing an operation of a method of manufacturing a displayapparatus according to another embodiment. Although cases ofmanufacturing a single display apparatus have been described above, theinventive concept is not limited thereto. For example, as shown in FIG.13, a case of fabricating a plurality of display cells “C” concurrently(e.g., simultaneously) and manufacturing a plurality of displayapparatuses is also within the scope of the inventive concept.

For example, a mother panel MP as shown in FIG. 13 may be formed byforming a plurality of displays apart from one another on the firstsubstrate 110 and adhering the first substrate 110 to the secondsubstrate 120 by using the sealing element 140. Here, the sealingelement 140 may surround each of the plurality of displays. In FIG. 13,it may be understood that the dotted lines indicating the respectivedisplay cells “C” indicate an area for arranging the sealing element140. Next, as shown in FIG. 14, a portion of the sealing element 140 maybe exposed. FIG. 14 may be understood as a sectional diagram showingportions of two display cells “C” adjacent to each other among theplurality of display cells “C” of FIG. 13. Next, a plurality of displayapparatuses having convex side surfaces may be manufactured by cuttingportions of the first substrate 110 and the second substrate 120 atpoints of the first substrate 110 and the second substrate 120corresponding to the exposed portion 141 of the sealing element 140(e.g., the points indicated as P3 in FIG. 14) by using a cutting wheel.

In a method of manufacturing a display apparatus in the related art,after the entire sealing element 140 is exposed, the first substrate 110and the second substrate 120 are cut at the center of portions of thefirst substrate 110 and the second substrate 120 between display cells“C” adjacent to each other, that is, the center of portions of the firstsubstrate 110 and the second substrate 120 between the sealing element140 of a first display cell “C” and the sealing element 140 of a seconddisplay cell “C” adjacent to the first display cell “C.” Therefore, tosecure cutting points, it is necessary to maintain a sufficient gap “G”between display cells “C,” and, thus, a number of display cells “C” thatmay be simultaneously formed on the mother panel MP is limited.

However, in a method of manufacturing a display apparatus, according tothe present embodiment, the first substrate 110 and the second substrate120 are cut along the dotted lines indicating the sealing element 140instead of cutting the first substrate 110 and the second substrate 120along portions between display cells “C.” Therefore, the gap “G” betweendisplay cells “C” may be further reduced as compared to the method inthe related art, and thus a number of display cells “C” that may beconcurrently (e.g., simultaneously) formed on the mother panel MP may beincreased. As a result, cost and time for manufacturing displayapparatuses may be significantly reduced.

Although FIG. 14 shows that the display cells “C” adjacent to each otherhave independent sealing elements 140, the inventive concept is notlimited thereto. For example, as shown in FIG. 15, which is a schematicsectional diagram showing an operation of a method of manufacturing adisplay apparatus, according to another embodiment, the display cells“C” adjacent to each other may share the sealing element 140. In thiscase, in case of exposing the sealing element 140 by using a photo maskincluding the phototransmissive plate 210 having formed thereat theblocking unit 150, only the exposed portion 141 of the sealing element140 arranged close to the display 130 may be exposed. The exposure maybe performed by arranging the blocking unit 150 in correspondence to thecenter of the sealing element 140. Next, at points of the firstsubstrate 110 and the second substrate 120 corresponding to the exposedportion 141 of the sealing element 140 (e.g., the points indicated as P3in FIG. 15), portions of the first substrate 110 and the secondsubstrate 120 are cut by using a cutting wheel, and thus a plurality ofdisplay apparatuses having convex side surfaces may be manufactured. Inanother embodiment, as a modification of the methods of manufacturing adisplay apparatus described above with reference to FIGS. 13 and 14, aphoto mask including the blocking unit 150 may be used.

According to the above-described embodiments of the inventive concept, adisplay apparatus with improved shock resistance and a method ofmanufacturing the same may be embodied. Furthermore, by manufacturing adisplay apparatus, according to an embodiment, degradation of equipmentsuch as a laser source may be reduced. However, effects of the inventiveconcept are not limited thereto.

It should be understood that embodiments described herein should beconsidered in a descriptive sense only and not for purposes oflimitation. Descriptions of features or aspects within each embodimentshould typically be considered as available for other similar featuresor aspects in other embodiments.

While one or more embodiments have been described with reference to thefigures, it will be understood by those of ordinary skill in the artthat various changes in form and details may be made therein withoutdeparting from the spirit and scope as defined by the following claims.

What is claimed is:
 1. A display apparatus comprising: a first substratecomprising a first inner surface and a first outer surface opposite tothe first inner surface; a second substrate comprising a second innersurface facing the first inner surface and a second outer surfaceopposite to the second inner surface; a display element between thefirst inner surface and the second inner surface, the display elementcomprising a light emitting diode and a thin-film transistor; a sealingelement located between the first and second substrates, and surroundingthe display element; and a touch pattern on the second outer surface;wherein the display apparatus comprises a side surface extending betweenthe first outer surface and the second outer surface and comprising acurved surface with respect to a direction from the first outer surfaceto the second outer surface.
 2. The display apparatus of claim 1,further comprising a plurality of line patterns that are disposed on thesecond outer surface.
 3. The display apparatus of claim 2, wherein theplurality of line patterns overlaps the sealing element.
 4. The displayapparatus of claim 3, wherein the plurality of line patterns comprises asame material as the touch pattern.
 5. The display apparatus of claim 1,wherein at least one of the first substrate or the second substratefurther comprises a side surface comprising a flat surface and a curvedsurface, the side surface of the display apparatus comprising the sidesurface of the at least one of the first substrate or the secondsubstrate, and the curved surface of the side surface of the displayapparatus comprising the curved surface of the side surface of the atleast one of the first substrate or the second substrate.
 6. The displayapparatus of claim 5, wherein a ratio of the flat surface with respectto the side surface of the at least one of the first substrate or thesecond substrate is less than that of the curved surface of the sidesurface of the at least one of the first substrate or the secondsubstrate with respect to the side surface of the at least one of thefirst substrate or the second substrate.
 7. The display apparatus ofclaim 5, wherein the curved surface of the side surface of the at leastone of the first substrate or the second substrate is curved in a firstdirection from the first or second outer surface to the sealing elementsuch that a vertex of the curved surface of the side surface of the atleast one of the first substrate or the second substrate is adjacent tothe sealing element.
 8. The display apparatus of claim 1, wherein thefirst substrate further comprises a first side surface connecting thefirst inner surface and the first outer surface, the first side surfacecomprising a first curved surface, and wherein the second substratefurther comprises a second side surface connecting the second innersurface and the second outer surface, the second side surface comprisinga second curved surface.
 9. The display apparatus of claim 8, whereinthe first curved surface is curved in a first direction from the firstouter surface to the first inner surface such that a vertex of the firstcurved surface is adjacent to the sealing element.
 10. The displayapparatus of claim 8, wherein the second curved surface is curved in asecond direction from the second outer surface to the second innersurface such that a vertex of the second curved surface is adjacent tothe sealing element.
 11. The display apparatus of claim 8, wherein thecurved surface of the side surface of the display apparatus comprises asubstantially continuous curved surface which includes the first curvedsurface, a side surface of the sealing element, and the second curvedsurface.
 12. The display apparatus of claim 8, wherein the first sidesurface further comprises a first flat surface, and the second sidesurface further comprises a second flat surface.
 13. The displayapparatus of claim 12, wherein a ratio of the first flat surface withrespect to the first side surface is less than that of the first curvedsurface with respect to the first side surface, and a ratio of thesecond flat surface with respect to the second side surface is less thanthat of the second curved surface with respect to the second sidesurface.